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Removal and installation of the cylinder head

The cylinder head of the diesel engine

1 - the number of spare parts; 2 - code; 3 - characteristics pads

The cylinder head must be removed on a cold engine. Removing the cylinder head is made together with the inlet and the exhaust manifold.

Burned or defective cylinder head gasket is determined by the following features:

- Reduction of engine power;
- Reduction of the coolant level. At the same time from the exhaust pipe goes white steam;
- Reducing the level of engine oil;
- The presence of oil in the engine coolant, thus increasing the oil level. In the presence of engine oil in the engine oil coolant becomes gray and has a foam bubbles;
- The presence of engine oil in the coolant;
- Intense release of bubbles from the cooling liquid;
- A reduction in the compression of two adjacent cylinders of the engine.

Withdrawal

PERFORMANCE ORDER

1. Check that the engine is cold. Otherwise, let the time to cool the engine. 2. Turn off the ignition and remove a wire of weight from the accumulator. SDI Engine 3. Remove the intake manifold. TDI engine 4. Remove the pipe connecting the radiator nadduvaemogo air intake manifold. 5. Drain the coolant from the cooling system. 6. Remove the front and left side of the cylinder head cooling system hoses and move them aside. 7. Disconnect the electrical connector from the oil pressure of 0.3 bar. 8. Remove the bus supply voltage on the glow plug. Remove the spark plugs. Clean the connecting pipes to the fuel injectors and high pressure fuel pump. Unscrew connecting nuts and remove the fuel. Close the holes with suitable plugs. 9. Remove the cylinder head of the fuel injectors. 10. Loosen or cut the clamp and remove the crankcase ventilation hose from the intake manifold. Release retaining clip and remove the crankcase ventilation hose from the engine block. Remove the O-ring. 11. Raise the vehicle. 12. Remove a reception exhaust pipe from the exhaust manifold or turbocharger. Using a soft wire, suspend reception exhaust pipe to a body. 13. Remove the top casing of a gear belt. 14. Loosen toothed belt and remove it from a camshaft pulley. 15. Loosen the bolt of a pulley of a camshaft on half of turn. Remove a pulley of a gear belt of a camshaft with a camshaft assembly cone using a drift through a hole in a back casing of a gear belt. Remove the bolt and remove the camshaft pulley. 16. Remove the bolts back casing of a gear belt. 17. In the sequence shown in the figure, loosen the bolts of the cylinder head half a turn, and then in the same sequence unscrew bolts. 18. Make sure that on the cylinder head and disconnect pipes, hoses and electrical connectors. 19. Remove the cylinder head from the engine and install it on two pieces of wood. When removing the head press the back casing of a gear belt. A warning Do not turn the camshaft in the cylinder head removed. If a camshaft mounted in the piston of the first cylinder at top dead center in the compression stroke, the cams of the camshaft of the first cylinder should be directed upward. In this position, the tool can be set to lock in the groove in the end face of the camshaft. 20. Remove the cylinder head gasket.

Setting

PERFORMANCE ORDER

1. The mating surface of the cylinder head and must be perfectly clean. For their clearing use a firm plastic or wooden scraper. When cleaning, be careful, as the aluminum alloy is very easily damaged. 2. Make sure that the deposit has not got to oil and water channels. This is especially important for greasing system as the deposit can block oil giving to engine components. If necessary, clean the channels. 3. Clean the bolt holes in the engine block. Tightening the screws in the aperture filled with oil can break off the block because of hydraulic pressure. 4. Using a metal ruler and a feeler gauge, check the flatness of the mating surfaces. 5. Deviation from the flatness should be less than 0.1 mm. 6. If the engine is equipped with new pistons, measure the protrusion of the pistons and the cylinder based on the amount of protrusion of the pistons to select the thickness of the new cylinder head gasket (see. Fig. Marking gasket cylinder head cover of the diesel engine). 7. When installing the cylinder head is necessary to use a new gasket. Remove the liner from the hermetic package immediately prior to installation on the cylinder block. 8. For the correct installation of the cylinder head and cylinder head gasket screw holes in the extreme cylinder intended for the bolts of the cylinder head, guide pins VW 3070. In the absence of the guide pins can be made independently, which requires the use of two old bolts the cylinder head. Cut off from the bolt head and instead cut the groove for screwdriver. After installation of the cylinder head, using a screwdriver, unscrew the guide pins. 9. Using a paint mark the installation position of the crankshaft pulley. Then turn the crankshaft 1/4 turn to any one of the pistons was not in the top dead center. Before installation the toothed belt is required to install the crankshaft position where the first cylinder piston is at TDC in the compression stroke. 10. Carefully install the cylinder head. 11. To the cylinder head, use only new bolts. Screw the bolts of the cylinder head by hand. 12. Use a screwdriver to remove the two guide pins in their place and screw the two mounting bolts of the cylinder head. 13. Gradually, in the sequence shown in the figure, in several stages, tighten head bolts tsilindrov.Stadiya 1 - 40 Nm. Step 2 - 60 Nm. Stage 3 - tighten on a corner 90 ?�. Stage 4 - tighten on a corner 90 ?�. 14. Further tightening of the cylinder head is not required. 15. Turn the crankshaft 1/4 turn so that the piston of the first cylinder established at TDC in the compression stroke. Check that the camshaft installed in the correct position for the installation of the piston of the first cylinder at TDC on the compression stroke. Grease working surface of the pusher and cam camshaft with clean engine oil. 16. Screw the bolts back casing of a gear belt. 17. Install the timing belt. A warning Remember to remove the locking tool of a pulley of the fuel pump. 18. Install the cylinder head cover and tighten the cap nuts to 10 Nm. 19. Install the top casing of a gear belt. 20. Attach a reception exhaust pipe to the exhaust manifold and the turbocharger. 21. Lower the car. SDI Engine 22. Install the inlet pipe. TDI engine 23. Place the tube between the radiator nadduvaemogo air inlet tube and secure it with clamps. 24. Connect the hose to the cylinder head. 25. Fill the engine cooling system fresh coolant. 26. Screw glow. 27. Screw the fuel injectors. 28. Connect the ground cable to the battery. 29. Check the engine oil level and, if necessary, finish it to norm. 30. Start the engine and warm it up to normal operating temperature. 31. Check the condition and tightness of the cooling system. 32. Check the injection timing of the fuel injection pump.